Structural insulated panel framing system

ABSTRACT

Systems and methods are disclosed herein to a structural insulated panel framing system comprising: insulation sheathing receivable by a wall jig; a frame for placement atop the insulation sheathing; and spray foam for application to the frame and the insulation sheathing to fuse the frame and insulation sheathing to produce a structural insulated panel.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application is a Continuation of U.S. Nonprovisionalapplication Ser. No. 15/488,477 filed 15 Apr. 2017, now U.S. Pat. No.10,760,270 issued 1 Sep. 2020; which is a Divisional of U.S.Nonprovisional application Ser. No. 13/897,145 filed 17 May 2013, nowU.S. Pat. No. 9,624,666 issued 18 Apr. 2017; which claims the benefit ofU.S. Provisional Application Ser. No. 61/648,980 filed 18 May 2012; eachof which is incorporated herein by reference in its entirety.

TECHNICAL FIELD

The present disclosure relates generally to structural panels, and moreparticularly, to a structural panel framing system without mechanicalfastening.

BACKGROUND

Conventional construction of a building is generally performed accordingto well-known processes. Near the beginning of the construction project,excavation equipment prepares a foundation at a job site. Once thefoundation is laid, building materials are brought to the job site, suchas wood, metal, cement, and other various building materials. Once theraw materials arrive at the job site, construction workers begin theprocess of erecting a frame at the job site. For example, when a houseis constructed, construction workers generally erect wooden framing forthe house. After the frame is completed, construction workers fastensheathing, such as plywood, that covers the outside of the frame usingmechanical fasteners, such as nails or screws. After the sheathing hasbeen fastened to the frame, the frames are raised into place to becomewalls. The walls later receive electrical and plumbing appliances,insulation, and drywall.

The conventional construction method of building walls and wall panelsrequires a great deal of construction work on the job site. Theconstruction workers must assemble a wall frame, attach sheathing, alterthe frame to accommodate electrical and plumbing appliances, and manyother steps all at the job site. If the weather is rainy or snowy,construction workers may be unable to build the walls and framing duringthat time, thereby losing construction time. So, a method of preparingwall panels before construction begins at the job site accelerates thetime to construct a building at the job site.

Some companies prepare structural panels in a factory and transportfully assembled structural panels to the construction site where thefully assembled structural panels are raised to form a wall for thebuilding. Some of these factory prepared structural panels areinsulated.

Conventional structural insulated panels require top and bottom panelsto be integrated or incorporated into the panel. This structure requiresan additional step during field installation. Typically, a bottom trackmust first be installed, a structural insulated wall panel inserted intothe bottom track, installing the top track, and fastening the structuralinsulated wall panel with stud members. This requires a significationamount of time and manpower, as well as slowing down the buildingprocess when using structural insulated panels. So, a structuralinsulated panel that overcomes the problems discussed above is desired.

SUMMARY

The systems and methods described herein attempt to overcome thedrawbacks discussed above by forming a structural insulated panelwithout mechanical fasteners. The structural insulated panel accordingto the exemplary embodiments may be formed in a factory. The structuralinsulated panel according to the exemplary embodiments may includepre-formed members of a frame that results in simple assembly of theframe. Also, the frame is pre-cut with pipe holes in the frame membersfor pipes to run through the panels and anchor holes for easyinstallation at the job site.

In one embodiment, a structural insulated panel framing systemcomprises: insulation sheathing receivable by a wall jig; a frame forplacement atop the insulation sheathing; and spray foam for applicationto the frame and the insulation sheathing to fuse the frame andinsulation sheathing to produce a structural insulated panel.

In another embodiment, a method for constructing a structural insulatedpanel comprises: fusing a frame and insulation sheathing using sprayfoam to produce a structural insulated panel, wherein the insulationsheathing is placed atop a wall jig, and wherein the frame is alsoplaced atop the wall jig in alignment with the insulation sheathing.

In another embodiment, a structural insulated panel comprises: exteriorinsulation sheathing; a frame engaging the exterior insulationsheathing; and spray foam sprayed within cavities of the frame such thatthe spray foam substantially covers internal surfaces of the cavitiesand fuses the frame to the exterior insulation sheathing.

Additional features and advantages of an embodiment will be set forth inthe description which follows, and in part will be apparent from thedescription. The objectives and other advantages of the invention willbe realized and attained by the structure particularly pointed out inthe exemplary embodiments in the written description and claims hereofas well as the appended drawings.

It is to be understood that both the foregoing general description andthe following detailed description are exemplary and explanatory and areintended to provide further explanation of the invention as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings constitute a part of this specification andillustrate an embodiment of the invention and together with thespecification, explain the invention.

FIG. 1 illustrates material layers comprising a structural insulatedpanel, according to an exemplary embodiment.

FIGS. 2A-2E illustrate an exemplary structural framework for thestructural insulated panel, according to an exemplary embodiment.

FIGS. 3A and 3B illustrate a wall jig used to assemble the structuralinsulated panel, according to an exemplary embodiment.

FIGS. 4A and 4B illustrate exterior insulation sheathing being placed ona wall jig, according to an exemplary embodiment.

FIGS. 5A and 5B illustrate a woven fiberglass mesh being applied to theexterior insulation sheathing, according to an exemplary embodiment.

FIGS. 6A-6D illustrate framing being positioned on the wall jig andfastened to the wall jig, according to an exemplary embodiment.

FIGS. 7A-7D illustrate holes and grommets in the structural frameworkfor electrical or plumbing appliances that extend through the structuralinsulated panel, according to an exemplary embodiment.

FIGS. 8A and 8B illustrate spray foam being applied to the structuralinsulated panel, according to an exemplary embodiment.

FIG. 9 illustrates a flow chart for assembling the structural insulatedpanel, according to an exemplary embodiment.

FIGS. 10A-10D illustrate connection plates and splice covers forenabling panel-to-panel connections between structural insulated panels,according to exemplary embodiments.

DETAILED DESCRIPTION

Reference will now be made in detail to the preferred embodiments,examples of which are illustrated in the accompanying drawings.

The embodiments described above are intended to be exemplary. Oneskilled in the art recognizes that numerous alternative components andembodiments may be substituted for the particular examples describedherein and still fall within the scope of the invention.

Referring to FIG. 1, FIG. 1 illustrates the material layers comprisingthe structural insulated panel 100. The structural insulated panel 100includes a structural framework 102, an exterior insulation sheathing104, an armor mesh 106, and closed cell spray foam 108.

The structural framework 102 may comprise metal studs or any otherframing materials, such as wood framing. The structural framework 102may comprise any automatic framing system, but preferably, thestructural framework 102 comprises cold-formed steel framing, such asthe Nuconsteel® Nuframe 3.5″ wide steel framing. Also, any size steelframe may comprise the structural framework 102. The structuralframework 102 may include steel frames of any steel gauge. For example,the structural framework 102 may have 20 gauge studs at 20 inches oncenter. The gauge and distance between studs may vary depending ondesign choices. The structural framework 102 may be riveted, screwed, orcrimped, depending on the steel stud manufacturers recommendation. Thestructural framework 102 includes studs, members, braces, blockings, andany other pieces necessary to construct the structural framework 102.The structural framework 102 may be formed and assembled beforeassembling the structural insulated panel 100, which is described ingreater detail below in reference to FIG. 2.

The exterior insulation sheathing 104 may be, but is not limited to,expanded polystyrene (EPS). The exterior insulation sheathing 104 mayalso comprise extruded polystyrene (XPS) or any other rigid sheathing.For example, if EPS sheathing is used, the EPS sheathing may have athickness of 1 inch, and a minimum density of 2 pounds per cubic foot.The exterior insulation sheathing 104 may come in a standard size of 4feet by 16 feet, but the exterior insulation sheathing 104 may be cutaccording to a specification for the panel. The exterior insulationsheathing 104 may also be cut for openings, such as doors or windows, orirregularities, such as if the panel 100 is not rectangular in shape.

The armor mesh 106 may comprise a woven fiber glass mesh material thatis applied to the external insulation sheathing 104 or embedded into theclosed cell spray foam 108. Preferably, the woven fiber glass materialcomprising the armor mesh 106 has a weight of 4.5 ounces per yard, butother weights may be used to form the armor mesh 106. The armor mesh 106may include other thicknesses, weights, or materials so long as theclosed cell spray foam 108 is able to circumvent or penetrate the armormesh 106 and glue together the exterior insulation sheathing 104, thestructural framework 102, and the armor mesh 106.

The closed cell spray foam 108 may generally be sprayed onto the othermaterial layers to a thickness of 1 inch. The closed cell spray foam 108may have any thickness, but the closed cell spray foam 108 may have atleast one inch thickness. The closed cell spray foam 108 may have adensity of 2 pounds per cubic foot. The closed cell spray foam 108 mayhave another density, but the closed cell spray foam 108 has a densityof at least 1.8 pounds per cubic foot. The density of the closed cellspray foam 108 may be chosen based on a desired impact resistance andr-value for thermal resistance.

In some embodiments, the structural insulated panel 100 furthercomprises open cell spray foam 110. The open cell spray foam 110 mayhave a density of 0.5 pounds per cubic foot. The open cell spray foam110 may have a thickness that depends on the width of the structuralframework 102. For example, if the structural framework 102 is 3.5″ indepth, the open cell spray foam 110 may have a maximum thickness of2.5″. The density of the open cell spray foam 110 may also be chosenbased on a desired impact resistance and r-value.

In some embodiments, the structural insulated panel 100 furthercomprises a drywall board 112. The drywall board 112 may comprise gypsumand may be coated with any common interior finish, such as paint or wallpaper. For example, the drywall board 112 may have a thickness of ½inch.

In some embodiments, the structural insulated panel 100 may furthercomprise an exterior insulation finishing system (EIFS) or stucco basecoat 114 and finishing coat 116, such as BASF® Synergy™ Alpha basecoatand BASF® Synergy™ finish coat, if the structural insulated panel 100includes EIFS or stucco. If the structural insulated panel 100 includesthe base coat 114, an open weave glass fiber reinforcement mesh mayembed the base coat 114. The finish coat 116 may included textured orcolored material, or the finish coat 116 may be 100% acrylic.

The base coat 114 and the finishing coat 116 are one example of anexterior surface that may be applied to the structural insulated panel100, but many other exterior finishes may be applied to the structuralinsulated panel 100, such as cement siding, metal siding, PVC siding,paint, or any other exterior finish.

Referring to FIGS. 2A-2E, FIGS. 2A-2E illustrate exemplary structuralframeworks 202B-E and structural framework components. As shown in FIG.2A, a plurality of framing components 230 may be formed using a rollformer. The roll former may include galvanized steel coils that assistin forming the framing components 230. A software application may beused to design the structural framework 202, and the software createddesign may be printed out using the roll former. The softwareapplication allows a designer to not only control the sizes, thickness,gauge, and distance between studs, but the software application alsoallows a designer to design for abnormalities into the structuralframework 202, such as holes 232 where electrical wiring, may extendthrough the structural insulated panel.

The roll former may create studs, blocks, beams, posts, bracings,strappings, or any other type of framing component 230 for inclusion inthe structural frameworks 202B-E. The framing components 230 are cut,punched, notched and pre-drilled to receive rivets or screws forassembly. When all the framing components 230 have been formed, theframing components 230 are assembled with a pop-riveter or an electricscrew gun based on the type of fasteners chosen to assemble thestructural framework 202. The structural frameworks 202 may befabricated to any length or height. FIGS. 2B-2E show a plurality ofdifferent structural frameworks 202B-E. As shown in FIGS. 2B-2E, theshape and structure of the structural frameworks 202B-E may varyaccording to design specifications. For example, the structuralframework 202D in FIG. 2D is cut for a window 234, and the structuralframework 202E in FIG. 2E is cut for a doorway 236. When forming theframe components 230, each frame component 230 may be pre-labeled withan alpha-numeric label. The labels on the frame components 230 may matchlabels from the software application, and the labels may assist inassembling the structural framework 202.

FIGS. 3A and 3B illustrate an exemplary wall jig 340 that may be used toassist in assembling the structural insulated panel. FIG. 3A illustratesa front view of the wall jig 340, and FIG. 3B illustrates a side view ofthe wall jig 340. As shown in FIG. 3A and 3B, the wall jig 340 includesa flat back panel 342 and a ledge 344. Components of the structuralinsulated panel may be placed on the ledge 344 and laid against the flatback panel 342. The flat back panel 342 may be angled so that componentsof the structural insulated panel may be leaned against the flat backpanel 342 during panel assembly. The flat back panel 342 and the ledge344 may each extend substantially perpendicularly to each other. Thewall jig 340 may be relatively tall, such as over 18 feet tall so thatthe wall jig 340 is taller than any structural insulated panel beingassembled using the wall jig 340. The flat back panel 342 may besurrounded by a metal locking bar 346. The metal locking bar 346 mayreceive tie bars, and the tie bars secure the panel components againstthe wall jig 340, which is described in greater detail with reference toFIGS. 6A-6B. The wall jig 340 may further include a clamping mechanismused to secure horizontal tie bars to the ledge 344.

FIGS. 4A-B illustrates two sections of the exterior insulation sheathing404 being laid against the wall jig 440. As shown in FIG. 4A, a sectionof exterior insulation sheathing 404 is being laid against the wall jig440, and in FIG. 4B, two sections of exterior insulation sheathing 404rest against the wall jig 440.

After placing the exterior insulation sheathing 404 on the wall jig 440,the armor mesh is applied to the exterior insulation sheathing 404.Referring to FIG. 5A and 5B, the armor mesh 506 is attached to theexterior insulation sheathing 504. The armor mesh 506 may be temporarilyattached to the exterior insulation sheathing 504 using mechanicalfasteners, such as nail tacks, glue, spray foam, or another adhesive. Insome embodiments, the armor mesh 506 comes as a roll, and the roll has awidth, such as 48 inches. The armor mesh 406 may be cut and applied tothe exterior insulation sheathing 504. When applying the armor mesh 506,the armor mesh 506 should overlap at least 3 inches at joints betweentwo strips of armor mesh 506. The armor mesh 506 reinforces the strengthof the exterior insulation sheathing 504. For example, in areas wherehurricane force winds occur regularly, the reinforcement provided by thearmor mesh 506 helps the structural insulated panel withstand such highwinds and strong forces.

After placing the exterior insulation sheathing 504 on the wall jig andplacing the armor mesh 506 on the exterior insulation sheathing 504, theexterior insulation sheathing 504 and the armor mesh 506 may be cut tomatch the design specifications. For example, the exterior insulationsheathing 504 and the armor mesh 506 may be cut for doors and windows.As a result of cutting the exterior insulation sheathing 504 and thearmor mesh 506, the exterior insulation sheathing 504 and armor mesh 506should match the structure of the assembled structural framing.

Referring now to FIGS. 6A-6D, after the exterior insulation sheathing604 and the armor mesh 606 have been cut according to the design of thepanel, the wall jig 640 receives the structural framework 602, as shownin FIG. 6A. As shown in FIG. 6A, the cut exterior insulation sheathing604 matches the assembled structural framework 602 in form, and thestructural framework 602 is placed on the wall jig 640 such that theform of the structural framework 602 and the cut exterior insulationsheathing 604 align.

Subsequently, the structural framework 602 and the exterior insulationsheathing 604 are not attached with the use of mechanical fastenings,such as nails or screws. Instead, as shown in FIG. 6B, vertical tie bars650 are clamped into the wall jig 640 to secure the structural framework602 to the exterior insulation sheathing 604 and prevent any movement ofthe structural framework 602 or the exterior insulation sheathing 604 onthe wall jig 640. FIG. 6C illustrates two vertical tie bars 650 securelyfixing the structural framework 602 to the wall jig 640.

In addition to the vertical tie bars 650, a horizontal spacer bar 652may be placed on the ledge 644 of the wall jig 640 against the bottom ofthe structural framework 602, which is illustrated in FIG. 6D. Thehorizontal spacer bar 652 secures a bottom member of the structuralframework 602 to the wall jig 640. A locking mechanism 654 locks thehorizontal spacer bar 652 against the structural framework 602.

The horizontal spacer bar 652 and the vertical tie bars 650 securelyclamp the structural framework 602 and the exterior insulation sheathing604, including the adhered armor mesh 606, to the wall jig 640 while aspray foam is applied. The application of the spray foam is described ingreater detail with reference to FIG. 8A and 8B. Once the structuralframework 602, the exterior insulation sheathing 604, and the armor mesh606 are locked into place on the wall jig 640, the spray foam may beapplied to fuse together the structural framework 602, the exteriorinsulation sheathing 604, and the armor mesh 606. After fusing thestructural framework 602, the exterior insulation sheathing 604, and thearmor mesh 606 using the spray foam, the tie bars 650 and the horizontalspace bar 652 are removed and are not included in the structuralinsulated panel.

Some structural insulated panels include appliances for plumbing orelectrical wiring. As described above, the structural framework 602 wasdesigned and cut according to a design that was mindful of suchelectrical or plumbing appliances. For example, the structural insulatedpanel may include pipes where plumbing fluid or electrical wires mayextend through the panel. FIGS. 7A-7D illustrate such electrical orplumbing appliances installed into a panel.

Referring to FIGS. 7A, the structural framework 702 has pre-cut holes732 that accommodate electrical or plumbing appliances. The holes 732were cut when forming the structural framework 702 components. Referringto FIG. 7B, the holes 732 may be installed with grommets 762, ifnecessary. A rigid pipe 764C may extend through the holes 732 andgrommets 762, as shown in FIG. 7C. For example, electrical wires mayextend through the rigid pipe 764C so that an electrician may easilywire a building erected using the structural insulated panels accordingto the exemplary embodiments described herein. FIG. 7C illustrates arigid pipe 764C extending horizontally, and FIG. 7D illustrates a rigidpipe 764D extending vertically. The rigid pipe 764C or 764D may extendin any direction so long as the structural framework 702 has beenpre-cut in preparation for the installation and extending direction ofthe rigid pipe 764C or 764D.

The rigid pipe 764C or 764D may be coated with a release agent thatprevents spray foam from adhering to the surface of the rigid pipe 764Cor 764D. The release agent may be lithium grease, polish wax, vegetableoil, other oils, or any other release agent that prevents the adhesionof spray foam. Other components in the structural insulated panel mayneed to be coated with the release agent other than the rigid pipe 764Cor 764D, depending on the structure of the structural insulated panel.After the application of the spray foam, the rigid pipe 764C or 764D andany other components coated with the release agent my be cleaned of anyspray foam clinging to the rigid pipe 764C or 764D before completingassembly of the structural insulated panel.

Referring to FIGS. 8A-8B, the closed cell spray foam 808 is appliedwithin stud cavities 870. The spray foam may be sprayed on using a sprayfoam reactor. The spray foam reactor may beat a two component spray foamcomprising icynene and spray polymer to approximately 130 degreesFahrenheit at 1500 pounds per square inch (psi) of pressure. Other lowtemperature and low pressure spray foam systems may be substituted forthe spray foam reactor described above, such as, for example, TVM® Foam,Tiger Foam™, Froth Pack™ foam.

The spray foam reactor connects to a spray foam gun 872 that is suppliedwith up to 160 psi of pressurized air, and the spray foam gun appliesspray foam 808 within the stud cavities 870 on top of the exteriorinsulation sheathing 804, the armor mesh 806, and the structuralframework 802. As shown in FIG. 8B, the spray foam 808 may substantiallycover the studs of the structural framework 802 as well as substantiallycover surfaces within the cavities 870. The applied spray foam 808 maysubstantially coat the exterior insulation sheathing 804, the armor mesh806, and the structural framework 802 to any thickness, but generallythe thickness of the spray foam 808 is approximately 1 inch thick.

By using spray foam to fuse the components of the structural insulationpanel rather than mechanical fasteners, the panel may be constructedvery quickly. Also, the closed cell spray foam provides thermalinsulation properties that help keep the structure cool or warmdepending on the season.

The open cell spray foam may fill the remaining cavities 870, but thisprocess of applying the open cell spray foam may occur at the job siteafter electrical, mechanical, and plumbing systems have been installedin the panel. Open cell spray foam may fill the cavities 870, or otherinsulation may fill the cavities 870. The open cell spray foam mayprovide further insulation. So, the insulation of the panel may beprovided by either the closed cell spray foam or the open cell sprayfoam.

Referring now to FIG. 9, a method 900 for creating a structuralinsulated panel is illustrated. Beginning in step 902, a softwareapplication is used to design the structural insulated panel. Thesoftware application allows a user to set the dimensions of the panel;account for any windows, doorways, or other irregularities; and specifythe location of any holes for wiring or plumbing appliances. After thesoftware application designs the panel, the software application createsa print map describing how to form all of the members, blocks, andbraces that comprise the structural framework. Using the map created bythe software application, all structural framework components are formedin step 904 using, for example, a roll former. After forming all thecomponents of the structural framework, the structural framework may beassembled using the formed framework components in step 906.Concurrently, previously, or subsequently to the forming and assemblingof the structural framework, the exterior insulation sheathing may belaid on the wall jig in step 908. Subsequently, the armor mesh may beapplied to the exterior insulation sheathing in step 910. If necessary,the exterior insulation sheathing and the armor mesh may need to be cutto accommodate doorways or windows or other design features, and thiscutting may be performed after the application of the armor mesh. Afterthe exterior insulation sheathing, the armor mesh, and the structuralframework are fully formed and prepared, the structural framing may beplaced on the wall jig in alignment with the exterior insulationsheathing in step 912. The structural framework may be secured againstthe exterior insulation sheathing using vertical tie bars, horizontalspacing bars, and locking mechanisms in step 914. After locking andsecuring the components to the wall jig, rigid pipes may be insertedthrough pre-cut holes for electrical or plumbing appliances. Finally, instep 916, a spray foam may be applied to the exterior insulationsheathing, the armor mesh, and the structural framework to fuse thesecomponents together without the use of mechanical fasteners. The appliedspray foam in step 916 may be closed cell or open cell spray foam, or acombination of both. The spray foam may be applied to a thickness of oneinch or more depending on a chosen r-value. Optionally, an open cellspray foam may further fill the cavities of the panel, and this optionalstep may be performed in a factory or at a job site. For example, theclosed cell spray foam may be applied to a thickness of 1 inch, and theopen cell spray foam may be applied to a thickness of 2.5 inches to fillthe cavities of the panel.

During installation at the job site, all panels have structural membersbuilt in, so additional bottom and top tracks are not necessary toinstall the panel at the job site. The bottom track of the structuralinsulated panel of the exemplary embodiments has pre-punched anchorholes so that no additional drilling is necessary to fasten the wall tothe foundation cement slab at the job site. Also, all studs line up witha truss layout designed before constructing the structural insulatedpanel of the exemplary embodiments. So, a top track is also unnecessary.

The structural insulated panel of the exemplary embodiments may furtherhave panel-to-panel connections with top track splice covers andconnection plates. As shown in FIG. 10A, a top track splice 1080 may bea C-channel that is at least 8 inches long. The top track splice 1080bridges over the top track of two adjacent panels 1000, 1001. The toptrack splice 1080 fastens to both adjacent structural insulated panels1000, 1001 using at least 4 screws. Exterior screws may be drilledthrough the exterior insulation sheathing.

Another panel-to-panel connection is illustrated in FIG. 10B. As shownin FIG. 10B, a connection plate 1082 may further connect adjacent panels1000, 1001. For example, 3″×3″ connection plates 1082 may be spreadevenly over the height of the panel, and each connection plate 1082 isscrewed into the frame of each panel. For example, the connection plate1082 has four holes for fasteners, and two fasteners are fastened toeach panel 1000, 1001. The connection plates may be placed inside oroutside of the building.

FIG. 10C illustrates an L-shaped connection plate 1084 for a twoperpendicular panels 1000, 1001. The L-shaped connection plate 1084connects two adjacent and perpendicular panels 1000, 1001. Like theconnection plate 1082 in FIG. 10B, the L-shaped connection plate 1084fastens twice to each panel 1000, 1001. The L-shaped connection plate1084 may be used at corners.

FIG. 10D illustrates a T-shaped connection plate 1086. At theintersection of three panels 1000, 1001, 1001P, the T-shaped connectionplate 1086 fastens to each of the three panels 1000, 1001, 1001P. Forexample, two fasteners may fasten the T-shaped connection plate 1086 toeach panel 1000, 1001, 1001P.

While three connection plates have been illustrated in FIGS. 10B-D,other connection plate shapes and configurations may be necessarydepending on the architecture of the building.

As described above, the structural insulation panels require simple andfast assembly of wall panels. The wall panel may be brought to the jobsite as a completed panel, and the pre-cut holes of the top and bottomtracks of the wall allow construction workers to quickly fasten walls toslabs, foundations, floors, ceiling, and other wall panels.

The embodiments described above are intended to be exemplary. Oneskilled in the art recognizes that numerous alternative components andembodiments that may be substituted for the particular examplesdescribed herein and still fall within the scope of the invention.

1. A framing system comprising: an structural insulated panel,comprising: an insulation sheathing; a frame comprising a top plate, abottom plate, a pair of outer studs, and an inner stud, wherein the pairof outer studs and the inner stud span between the top plate and thebottom plate, wherein each of the outer studs and inner stud has aproximal side and a distal side, wherein the inner stud is positionedbetween the pair of outer studs; a mesh coupled to the insulationsheathing, wherein each of the distal sides of the outer studs and thedistal side of the inner stud abuts the mesh; and a cured spray foamadhering the insulation sheathing and the mesh to the frame such thatthe insulation sheathing, the mesh and the frame are unitary, whereinthe insulation sheathing and the mesh are coupled to the frame withoutmechanical fasteners.
 2. The framing system of claim 1, wherein theinsulation sheathing is a first insulation sheathing, and wherein theproximal sides of the outer studs and the proximal side of the innerstud are configured to abut a second sheathing.
 3. The framing system ofclaim 1, wherein the frame includes at least one of a framing member, abrace, and a blocking, wherein the at least one of the framing member,the brace, and the blocking is configured to receive at least one of arivet and a screw.
 4. The framing system of claim 1, wherein theinsulation sheathing comprises expanded polystyrene.
 5. The framingsystem of claim 2, wherein the mesh is interposed between the insulationsheathing and the frame.
 6. The framing system of claim 1, wherein thespray foam comprises a closed cell spray foam.
 7. A method, comprising:positioning an insulation sheathing on a wall jig; positioning a frameon the wall jig in alignment with the insulation sheathing; dispensingspray foam within the frame and onto the frame and the insulationsheathing; and fusing the insulation sheathing to the frame using thespray foam to produce a unitary structural insulated panel, wherein theinsulation sheathing is coupled to the frame without mechanicalfasteners.
 8. The method of claim 7, further comprising: generating amap for forming the frame from frame components using a softwareapplication.
 9. The method of claim 8, further comprising: forming theframe components using a roll former according to the map created by thesoftware application; and assembling the frame components to form theframe.
 10. The method of claim 7, further comprising: applying a mesh toa first side of the insulation sheathing before placing the frame on thewall jig, wherein the first side of the insulation sheathing faces theframe.
 11. The method of claim 10, further comprising: cutting theinsulation sheathing and the mesh so that the insulation sheathing andarmor mesh match the dimensions and configuration of the frame.
 12. Themethod of claim 7, further comprising: inserting a pipe through pre-cutholes in the frame so that the pipe extends through the structuralinsulated panel.
 13. The method of claim 7, further comprising: lockingthe frame and the insulation sheathing to the wall jig using a verticaltie bar that clamps into the wall jig and a locking mechanism that locksa horizontal spacer bar to the wall jig.
 14. The method of claim 7,wherein the spray foam is a closed cell spray foam.
 15. The method ofclaim 14, further comprising: spraying an open cell spray foam withincavities of the structural insulated panel that are not filled by theclosed cell spray foam, the insulated sheathing, or the frame.
 16. Astructural insulated panel, comprising: an insulation sheathing; a framecomprising a top plate, a bottom plate, a pair of outer studs, and aninner stud, wherein the pair of outer studs and the inner stud spanbetween the top plate and the bottom plate, wherein each of the outerstuds and inner stud has a proximal side and a distal side, wherein eachof the distal sides of the outer studs and the distal side of the innerstud abuts the insulation sheathing, wherein the inner stud ispositioned between the pair of outer studs; and a spray foam sprayedwithin cavities of the frame such that the spray foam substantiallycovers internal surfaces of the cavities and fuses the frame to theinsulation sheathing when cured such that the insulation sheathing andthe frame are unitary, wherein the insulation sheathing is coupled tothe frame without mechanical fasteners.
 17. The structural insulatedpanel of claim 16, further comprising a mesh in contact with the sprayfoam, wherein each of the distal sides of the outer studs and the distalside of the inner stud abuts the mesh such that the insulationsheathing, the frame, and the mesh are unitary.
 18. The structuralinsulated panel of claim 16, wherein the insulated sheathing comprisesan expanded polystyrene.
 19. The structural insulated panel of claim 16,wherein the spray foam is a closed cell spray foam.
 20. The structuralinsulated panel of claim 19, wherein a density of the closed cell sprayfoam is at least 1.8 pounds per cubic foot.
 21. The structural insulatedpanel of claim 19, further comprising: an open cell spray foam fillingthe cavities of the frame.
 22. The structural insulated panel of claim21, wherein the open cell spray foam has a density of 0.5 pounds percubic foot or less.
 23. The framing system of claim 1, wherein the meshis a first mesh, wherein the structural insulated panel furthercomprises a second mesh, wherein the first mesh contacts the spray foamsuch that the insulation sheathing, the frame, and the first mesh areunitary, wherein the insulation sheathing is interposed between thefirst mesh and the second mesh.
 24. The framing system of claim 1,further comprising: a wall jig; a tie bar removably coupled to the walljig, wherein the wall jig supports the insulation sheathing and theframe, wherein the tie bar secures at least one of the insulationsheathing and the frame to the wall jig.
 25. The framing system of claim1, further comprising: a wall jig; a spacer bar removably coupled to thewall jig, wherein the wall jig supports the insulation sheathing and theframe, wherein the spacer bar secures the frame to the wall jig.
 26. Theframing system of claim 25, further comprising: a removable lockingmechanism coupled to the wall jig, wherein the locking mechanism locksthe spacer bar against the frame.
 27. The framing system of claim 1,further comprising: a wall jig; a tie bar removably coupled to the walljig; a spacer bar coupled to the wall jig, wherein the wall jig supportsthe insulation sheathing and the frame, wherein the tie bar secures atleast one of the insulation sheathing and the frame to the wall jig,wherein the spacer bar secures the frame to the wall jig.
 28. Theframing system of claim 27, further comprising: a locking mechanismcoupled to the wall jig, wherein the locking mechanism locks the spacerbar against the frame.
 29. The structural insulated panel of claim 17,wherein the mesh is interposed between and abuts the insulated sheathingand the frame.
 30. The structural insulated panel of claim 16, furthercomprising: a first mesh abutting the frame and contacting the sprayfoam such that the spray foam fuses the first mesh to the frame and theinsulation sheathing when cured such that insulation sheathing, theframe, and the first mesh are unitary, a second mesh coupled to theinsulation sheathing such that the insulation sheathing is interposedbetween the first mesh and the second mesh.
 31. The structural insulatedpanel of claim 16, wherein the insulation sheathing is a firstinsulation sheathing, and wherein the proximal sides of the outer studsand the proximal side of the inner stud are configured to abut a secondsheathing.
 32. The structural insulated panel of claim 1, furthercomprising an appliance extending through the inner stud and the outerstuds via a hole through each pair of open ends such that the applianceis positioned between the top plate and the bottom plate.
 33. Thestructural insulated panel of claim 32, wherein the appliance is coatedwith a release agent that prevents adhesion of spray foam, such that theappliance is removable.
 34. The structural insulated panel of claim 1,wherein the inner stud and the outer studs comprise an open shapedstructure.
 35. The structural insulated panel of claim 34, wherein theinner stud and the outer studs comprise steel.
 36. The structuralinsulated panel of claim 34, wherein the open shaped structure is atleast one of a C-shaped or I-shaped structure.
 37. The framing system ofclaim 1, wherein the insulation sheathing and the mesh are coupled tothe frame using only cured spray foam or adhesive.
 38. The framingsystem of claim 1, wherein the insulation sheathing and the mesh arecoupled to the frame using only cured spray foam.
 39. The structuralinsulated panel of claim 16, wherein the insulation sheathing is coupledto the frame using only spray foam or adhesive.
 40. The structuralinsulated panel of claim 16, wherein the insulation sheathing is coupledto the frame using only cured spray foam.